Filler strip for door frames

ABSTRACT

THIS DISCLOSURE RELATES TO FILLER STRIPS WHICH ARE APPLIED TO THE FREE EDGES OF SHEET METAL DOOR FRAMES IN ORDER TO COMPENSATE FOR DISPARATE WALL THICKNESSES ABOUT A DOOR OPENING. THE TYPICAL SHEET METAL FRAME FOR WHICH THE FILLER STRIP IS INTENDED, COMPRISES A PAIR OF VERTICAL JAMB MEMBERS AND THE HORIZONTAL HEADER, THE MEMBERS BEING GENERALLY OF U-SHAPE CONFIGURATION, HAVING SLIGHTLY YIELDABLE LIMBS. THE FREE EDGES OF THE LIMBS EACH INCLUDE AN INTURNED FLANGE EXTENDING TOWARD ONE ANOTHER, WITH A RIGHT ANGULAR LIP EXTENDING FROM THE INNER EDGE OF EACH FLANGE. THE FILLER STRIP IS GENERALLY U-SHAPED IN CROSS SECTION AND NESTS SNUGLY ABOUT THE INTURNED FLANGE AND ANGULAR LIP OF THE DOOR FRAME MEMBERS SO AS TO DELINEATE A THROAT OPENING CORRESPONDING TO THE WALL THICKNESS ABOUT THE MARGINAL PORTION OF THE DOOR OPENING. THE FILLER STRIPS ARE FURNISHED IN VARIOUS THICKNESSES AND ARE SELECTIVELY MOUNTED UPON THE FRAME MEMBERS TO COMPENSATE FOR VARIATIONS IN WALL THICKNESSES, THE FILLER STRIPS BEING SELECTIVELY APPLIED ACCORDING TO DISPARATE WALL THICKNESS AS ENCOUNTERED IN THE FIELD AT INSTALLATION OF THE DOOR FRAME MEMBERS.

March 2, 1971 R. o. RUFF 3,566,563

FILLER STRIP FOR DOOR FRAMES Filed Nov. :12, 1968 v 2 Sheets-Sheet 1 INVENTOR.

March 2, 1971 R. o. RUFF 3,566,563

I FILLER STRIP FOR DOOR FRAMES Filed Nov. :12, 1968 2 Sheets-Sheet Z United States Patent 3,566,563 FILLER STRIP FOR DOOR FRAMES Robert O. Ruff, Cincinnati, Ohio, assignor to Steelcraft Manufacturing Company, Cincinnati, Ohio Filed Nov. 12, 1968, Ser. No. 774,877 Int. Cl. E061) 1/20 US. Cl. 52-211 2 Claims ABSTRACT OF THE DISCLOSURE This disclosure relates to filler strips which are applied to the free edges of sheet metal door frames in order to compensate for disparate wall thicknesses about a door opening. The typical sheet metal frame for which the filler strip is intended, comprises a pair of vertical jamb members and the horizontal header, the members being generally of U-shape configuration, having slightly yieldable limbs. The free edges of the limbs each include an inturned flange extending toward one another, with a right angular lip extending from the inner edge of each flange.

The filler strip is generally U-shaped in cross section and nests snugly about the inturned flange and angular lip of the door frame members so as to delineate a throat opening corresponding to the wall thickness about the marginal portion of the door opening. The filler strips are furnished in various thicknesses and are selectively mounted upon the frame members to compensate for variations in wall thicknesses, the filler strips being selectively applied according to disparate wall thickness as encountered in the field at installation of the door frame members.

BACKGROUND OF THE INVENTION The invention relates generally to door frames formed of sheet metal which are of sectional construction and is directed in particular to a sectional door frame adapted to be installed within the door opening of a building wall after the wall is erected.

Generally speaking, a sectional door frame constructed in accordance with the invention, comprises a horizontal header adapted to be mounted across the top of the door opening, a vertical hinge jamb adapted to be installed along one side of the door opening, and a vertical strike jamb adapted to be installed along the opposite side of the door opening. The door opening is framed by studs, in the present example, formed of sheet metal.

In the disclosure selected to illustrate the principles of the invention, the sheet metal door frames are installed in relation to a wall formed of prefabricated panels, generally called a dry wall," in which the panels are attached to the wall studs in place of plaster lath. In many instances, a skim coat of plaster is applied to the dry wall panels to provide a finished appearance.

The header and jambs of the sheet metal sectional door frame are generally channel-shaped in cross section and are arranged to overlap the wall panels or skim plastic coat on marginally opposite sides of the wall at the door opening, the sections being anchored securely in place with reference to the wall opening by mounting devices, as explained later.

One of the primary objectives of the invention has been to provide a filler strip which may be applied to the free edge portions of the door frame members (jambs and header) in the field to compensate for variations which may exist in the thickness of the wall in the marginal area surrounding the door opening, thereby to provide a finished appearance.

According to this concept, the door frame members are installed in the field after the wall has been erected, with the door opening formed therein. In many cases, there 3,566,563 Patented Mar. 2, 1971 exists a disparity in the thickness of the erected dry wall due to the use of panels of diverse thickness. In addition, variations in wall thickness may exist because of the thickness of a skim plaster coat which may have been applied to the dry wall panels. Ordinarily this variation creates a problem due to the fact that the sectional door frame members are provided with an accurately dimensioned throat opening, that is, the opening existing across the free end portions of the channel-shaped door frame members.

In the event of such a variation in wall thickness, the filler strips of the invention are applied selectively to the free edge portion of the door frame members in order to take up any space which may otherwise exist between the free edge portions of the framing members and the surfaces of the wall.

A further objective of the invention has been to provide filler strips having diverse thicknesses, whereby the strips may be selectively applied to the free edge portions (throat opening) of the door frame members to provide a selection in the adjustment of the throat opening to compensate for various fractional variations in wall thickness.

A still further objective has been to provide a filler strip which preferably is formed of a relatively rigid plastic material; a strip which may be installed conveniently upon the free edges of the channel-shaped door frame members; and in which the exposed portion of the filler strip snugly embraces the exposed surface of the door frame member to provide a neat, trim appearance.

According to this aspect, the free edge portion of the limbs of the channel-shaped, sheet metal frame members include flanges projecting inwardly toward one another, the inner edge of each flange including a right angular lip turned inwardly from the flange and arranged to reside in parallelism with the surface of the wall. The filler strip has a generally U-shaped or channel-shaped configuration, comprising a web and a pair of limbs generally parallel with one another, with an intermediate retaining flange projecting from one of the limbs towards the opposed limb. One of the limbs is feathered in cross section and is curved inwardly toward the opposed limb. This limb is slightly flexible and, upon installation of the strip, is sprung outwardly a sufiicient distance to embrace the exposed surface of the inturned flange under pressure to provide the finished appearance.

The filler strip is installed by slipping it longitudinally upon the door frame members so as to extend for the full length of the members. In its installed position, each filler strip nests upon the inturned flange and its right angular lip, with the feathered limb in pressure engagement with the exposed surface of the flange, while the web of the filler strip embraces the wall surface, thus providing a close fit with the wall and providing a finished appearance. In order to accommodate the variations in wall thickness, selected strips, the web portion of which vary in thickness, are installed to provide a throat opening which corresponds with the wall thickness.

The various features and advantages of the invention will be more fully apparent to those skilled in the art from the following description taken in conjunction with the drawings:

DRAWINGS FIG. 1 is a diagrammatic view of a door frame which includes the filler strips used in adjusting the frame to a dry wall door opening. In this view, the right-hand jamb and header are shown installed in the opening, with the left-hand jamb pivotally connected to the opposite end of the header for pivotal installation.

FIG. 2 is a view similar to FIG. 1, showing the lefthand jamb pivoted to its vertical position within the door opening to complete the frame assembly.

FIG. 3 is a sectional view taken along the line 33 of FIG. 1, showing a section of the door jamb and related wall section as the jamb is pivoted relative to the header to embrace the marginal edge portion of the door opening.

FIG. 4 is a sectional view taken along the line 44 of FIG. 2 showing the left-hand jamb in its final position with its open throat portion and filler strip embracing the opposite sides of the wall.

FIG. is a sectional view similar to FIG. 4, showing the arrangement of two of the filler strips mounted within the throat opening of the jamb (or header), illustrating the selective use of the filler strips.

FIG. 6 is a view similar to FIG. 5, showing the use of filler strips having disparate thicknesses to accommodate walls having thicknesses which vary from nominal dimen- SlOIlS.

FIG. 7 is an enlarged fragmentary perspective view illustrating one of the selective filler strips of this invention.

FIG. 8 is a fragmentary perspective view illustrating the preferred method of applying the filler strip to the flange of one of the sheet metal door jambs or header sections.

FRAME STRUCTURE GENERALLY As best shown in FIGS. 1 and 2, a metal door frame disclosing the utility of the filler strip is indicated generally at 1 in relation to the door opening 2 of a wall structure 3. The wall 3, by way of example, represents an internal dry wall partition, with vertical studs 4 (FIGS. 3-6), and with prefabricated plaster board panels 5-5 secured to the opposite sides of the studs. In the example illustrated, the studs 4 are formed of sheet metal having a U-shaped configuration in cross section, although the dry wall 3 may include the conventional wood studs (not shown).

It will be understood that the filler strip or strips of this invention, indicated generally at 6 (FIGS. 3-6), are also intended to be utilized in door frames which are installed in the external walls of a building.

A conventional dry wall partition utilizes prefabricated panels which may be disparate in thickness, as explained later. In many buildings, a skim coat of plaster is applied over the dry wall panels. The skim coat may also vary from a nominal thickness, thus introducing another variable factor. In a conventional plastered wall, the wall thickness about the door opening may also vary considerably from the nominal dimension.

Since the prefabricated sheet metal door frame members are furnished preferably with a predetermined throat opening, as indicated at T in FIG. 8, the filler strips 6 of the invention are conveniently applied to the throat opening to compensate for the wall variations. As described later, the filler strips 6 are furnished in a variety of thicknesses which may be used in combination with one another to provide the necessary accommodation to the wall thicknesses which may be encountered in the field.

As best shown in FIGS. 1 and 2, the door frame 1, which has been selected to illustrate the use of the filler strip 6 of this invention, is formed of sheet metal, comprising a horizontal header 7 which is mounted across the top of the door opening, with a pair of vertical jambs 88 to complete the door frame.

The meeting ends of the header 7 and the jambs 8-8 are mitered as at 10 in the usual way, so as to interfit one another upon assembly within the door opening. The mitered ends of the jambs 8-8 and header 7 are held in alignment with one another by means of respective hinge connectors (not shown), the arrangement being such that the frame is installed within the door opening by placing the header 7 in position and by hingedly connecting the upper ends of the jambs 8-8 to the mitered ends of the header 7. After the connection is made, the jambs are pivoted about the opposite ends of the header 7 to their vertical position, as indicated by the arrow in FIG. 1.

After the jambs 8-8 have been installed in their upright positions, their lower ends are secured permanently within the door opening 2 by means of base anchors, in dicated generally at 11, which are secured to the lower end portions of the jambs 88 (FIG. 1). The base anchors, which are not disclosed in detail, are generally U- shaped and are dimensioned to embrace the opposite sides of the U-shaped studs 4 of the door opening. The jambs -88 may also include top anchors (not shown), arranged to seat against the studs 4. The top anchors are adjustable by means of captive screws which, upon being tightened, force the upper mitered ends of the jambs 8 into pressure engagement with the opposite mitered ends of the header 7.

A hinge-type connection device, providing the pivotal connection between the ends of the header 7 and jambs 88, is disclosed in the US. Pat. 3,222,833 issued to Harold L. Woodrum on Dec. 14, 1965. This patent discloses in detail a base anchor along the lines of the base anchors 11 in the present application and also a top anchor (not shown in the present application). It will be understood that the filler strip 6 of the present invention may be utilized in connection with sheet metal door frames with mounting devices other than those which are disclosed in the prior patent.

SHEET METAL IAMB AND HEADER CONSTRUCTION In the door frame illustrated in FIGS. 3-6 and 8, the vertical jambs 88 and horizontal header 7 are generally channel-shaped in cross section, each having limbs 1212 which embrace the wall panels 55 (on wall surfaces) upon being installed within the door opening, as indicated in FIGS. 1 2. The header 7 and jambs 88 may be fabricated by a stamping operation, the header and jambs being of identical configuration in cross section.

In the present example, the header and jambs are of the double rabbet type, including a door stop 13 delineating the opposed rabbets 14-14. The door (not shown) may be hinged on either side of the stop 13, depending upon the required direction of door swing.

The opposed limbs 12-12 (FIGS. 3-6) of the header 7 and jambs 88, at their free edge portions, each include an inturned flange 15, each flange including a right angular lip 16 which, upon installation of the frame members 7 and 8, reside in parallelism with the surfaces of the Wall panels 55.

FILLER STRIP Described in detail, the filler strip, previously indicated at 6, is fabricated from a plastic such as vinyl or an equivalent non-metallic material, preferably by the extrusion process. The plastic material is relatively rigid or, if desired, it may be flexible. In the use of a rigid material, the filler strip 6, which is applied to the inturned flange 15 and lip 16 of the header and jambs, by slipping the filler strip 6 in a lengthwise direction of the jamb and header members, as indicated by the arrow in FIG. 8. If the filler strip 6 should be fabricated from a more flexible material, then it may be slipped upon the inturned flange 15 and lip 16 in a lateral direction, that is, by clinlching the filler laterally upon the inturned flange and 1ts ip.

Described in-detail, with particular reference to FIGS. 7 and 8, the filler strip 6 comprises a main body Which is generally U-shaped in cross section. The U-shaped body section comprises a pair of legs 17 and 18 which are parallel with and spaced apart from one another. The legs 17 and 18 of the strip are connected by a web section 20 which completes the U-shaped configuration. Leg 17 of the strip includes an intermediate retaining flange 21 projecting inwardly from leg 17 toward leg'18 and spaced therefrom as at 22. The leg 18 of the filler strip 6 (FIG. 7) is curled or feathered as at 23 in order to provide a finished appearance with reference to the inturned flange 15 of the door frame members 7 and 8 (FIG. 8). The inner surface of the feathered portion 23 is curved in wardly, as indicated at 24 so as to be sprung outwardly upon installation, thereby to embrace the surface of the inturned flange 15. The free edge of the feathered portion 23 terminates in a knife-edge 28 (FIG. 7) to provide a line contact with the surface of the flange 15.

As shown in FIGS. 6 and 8, the filler strip 6 is installed upon the inturned flange and its lip 16 (which are right angularly related), such that the inturned flange 15 and lip 16 (FIG. 8) nest within the right angular space existing within the strip 6. The inturned flange 15 thus extends through the space 22 (FIG. 7) existing between the feathered limb 18 and the inner end of the retaining flange 21, while the lip 16 extends into the space 25.

As shown in FIG. 7, the inner edge of retaining flange 21, in cross section, has a curved configuration 26 which facilitates the installation of the filler strip 6 upon the flange 15 and lip 16. As best shown in FIGS. 7 and 8, upon installation, the inner edge 27 of the limb 17 of the filler strip 6 resides in engagement with the inner surface of the yieldable sheet metal limb 12 of the header 7 and jambs 8. It will be understood that the filler strips are furnished in a variety of thicknesses in order to compensate for the different wall thicknesses to which the framing members 7 and 8 are to be applied.

INSTALLATION As noted above, the filler strip of the invention is furnished to the user in several sizes for selective installation upon the door frame members as required at installation. In each case the tiller strips are identical in cross section except that the thicknesses of the web section are varied for selective use.

By way of example, the dry wall panels may be furnished to the user in thicknesses of three-eighths inch, one-half inch, and five-eighths inch. There are also panels used which are irregular, for example, one-fourth inch in thickness. The builder, according to his requirements, may select wall panels of any one of the several thicknesses or in a combination of thicknesses. Moreover, in some instances, as noted above, a skim coat may be applied to the external surfaces of the wall panels, thus introducing a further variable factor.

In order to accommodate these differences, the filler strips are furnished, in the present example with web sections 20 which vary in increments ranging from one-eighth to one-quarter inch or greater. With one-eighth increments, it is feasible to accommodate variations of oneeighth in the overall thickness of the wall, which, combined with the slight flexibility of the sheet metal limbs 1212 of the door frame members is suflicient.

In the installation shown in FIGS. 3 and 4, in which the wall panels 55 are of a given thickness, a single filler strip 6, which may have a minimum web thickness, is installed upon one limb of the jambs and header. In other cases, for example, the installation shown in FIG. 5, two filler strips 6 having webs corresponding in thickness are shown installed in position.

FIG. 6 illustrates diagrammatically one of the conditions of wall construction which may require two filler strips having webs of diverse thickness. Thus one of the wall panels 5 may be of a maximum thickness as indicated at A, while the opposed panel may represent a minimum thickness, as indicated at C. In order to center the door stop 13 with reference to the overall wall, a filler strip 6 having a web of a minimum thickness, indicated at B is installed to coact with the A thickness wall panel, while a second filler strip 6 having a maximum web thickness, indicated at D, is installed to seat against the thin panel of C thickness. It will be apparent that various combinations of filler strips are selectively applied to the door frame members to impart convenience and flexibility in the installation of the sheet metal framing sections in the field.

Having described my invention, I claim:

1. A sectional door frame formed of sheet metal for mounting about the marginal portion of the door opening of a wall, said door frame comprising:

a pair of vertical jambs;

a horizontal header;

said jambs and header constituting frame members adapted to be installed marginally within the door opening of the wall;

said jambs and header being generally channel-shaped in cross section providing a web and a pair of parallel spaced limbs projecting from the web;

the free edges of said limbs each including an inturned flange projecting inwardly toward one another;

a right angular lip projecting inwardly from said inturned flanges toward the Web, said right angular lips delineating a throat opening adapted to embrace the opposite sides of the wall about the door opening;

a filler strip formed of non-metallic material fitted upon the inturned flange and right angular lip of at least one limb of said jamb and header;

said filler strip being generally U-shaped in cross section and having a web portion seated upon the right angular lip of the frame member;

a first leg projecting from one edge of the web portion of the filler strip inwardly toward the limb of the frame member and having a free inner edge engaging the inner surface of said limb;

said first leg having an intermediate retaining flange parallel with said web and embracing the side of the right angular lip opposite the Web, whereby the inturned lip is engaged between the web and retaining flange, said retaining flange having an inner end engaging the internal surface of the inturned flange;

a second leg projecting from the opposite edge of the web portion of the filler strip;

said second leg of the filler strip having a free edge projecting inwardly beyond said retaining flange and in substantial alignment with the free edge of said first leg;

said second leg being in pressure engagement with the external surface of the inturned flange of the frame member, whereby the inturned flange is engaged between the inner end of the retaining flange and second leg of the filler strip;

said web portion of said filler strip adapted to engage one surface of the wall about the marginal portion of the door opening and thereby to regulate the size of the throat delineated by the jambs and header.

2. A sectional door frame formed of sheet metal for mounting about the marginal portion of the door opening of a wall, said door frame comprising:

a pair of vertical jambs;

a horizontal header;

said jambs and header constituting frame members adapted to be installed marginally Within the door opening of the Wall;

said jambs and header being generally channel-shaped in cross section providing a web and a pair of parallel spaced limbs projecting from the Web;

the free edge portions of the limbs of the frame members each including an inturned flange, said flanges projecting inwardly toward one another;

a right angular lip projecting inwardly from said inturned flanges generally at right angles thereto;

a filler strip of generally U-shaped cross section having a web portion seated upon said right angular lip of at least one limb of said jamb and header;

said filler strip having a first leg projecting from the Web of the filler strip inwardly toward the limb of the frame member, and having a free inner end engaging the inner surface of the limb of the frame member;

said first leg of the filler strip including an intermediate retaining flange generally parallel with said web and embracing the opposite side of the right angular lip;

said intermediate retaining flange having an inner end engaging the inner surface of the inturned flange;

said filler strip having a second leg projecting from the opposite edge portion of the Web thereof;

said second leg of the filler strip having an inner surface which curves inwardly toward the surface of said inturned flange of the frame member;

said second leg being feathered from the web toward the outer edge of the leg;

the free end of the second leg having a knife edge in pressure engagement against the external surface of the inturned flange of the frame member;

the web portion of the filler strip engaging the surface of the wall marginally about the door opening and regulating the width of the said throat opening.

8 References Cited UNITED STATES PATENTS 5/1954 Carter 52211X 12/1954 Beck 52211X 12/1956 Kelly 52-212 12/1965 Woodrum 52211 10/1967 Nehlig.

ALFRED C. PERHAM, Primary Examiner US. Cl. X.R. 

